3rd IFCE 2010

INDUSTRIALIZING PAKISTAN

ELEMENTYour Guide to Foundries in Pakistan

www.pfa.org.pk 1st Qtr. 2011

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President Message

Sikandar Mustafa KhanPresident – PFA

Chief EditorMr. Fahad IqbalJoint Secretary - PFA

EditorMr. Abdul WaheedG.M. FoundryPakistan Engineering Company Limited(PECO)Kot Lakhpat, LahorePh: +92 42 35880071-4 Cell: 92 321 4989797Email: pecoklw@gmail.com

CoordinatorMr. Abdul RashidSecretary - PFA93-B, Hali Road, Gulberg-II, Lahore PakistanPh: +92 42 35023525, 35753619 Fax: 92 42 35755743Cell: +92 322 8487873Email: info@pfa.org.pkpakistanfoundryassociation@gmail.comURL: www.pfa.org.pk

It is a matter of great satisfaction for me that Pakistan Foundry Association has successfully organized the 3rd International Foundry Congress & Exhibition at Pearl Continental Hotel Lahore on December 01 & 02, 2010. It was largely attended by around 3000 foundrymen, Engineers, Technical Managers, Exhibitors, Buyers, Sellers and Students etc from all walks of Industrial Sector in Pakistan. This year we had an ever increased participation by local & overseas all those who are concerned with the Foundry Industry.

The participation from foreign countries i.e. Turkey, India, China, UK, Czech Republic etc was encouraging for us. Few important visitors Mr. Basar Oztopcular - Cukurova Kimya End. A.S, Turkey, Mr. Chavan Pruthviraj Ravindra, Mr. Shinde Sunil Shivajirao, Mr. Singh Subodh Rajan, Mr. Vinay kumar luthra - Gargi Huttenes-Albertus (Pvt) Ltd -India, Mr. Vikas - Director Marketing and Mr.

Ashok Sharma -Engineer Megatherm-India and many more. I highly acknowledge their participation as they travelled all the way for this event.

Since our first IFCE 2006 the PFA has gained the attention of the Foundry Industry globally and now IFCE is becoming one of the most important event in the region. Special added feature this year was more focused platform for local & International sourcing. A very encouraging response from the major casting users like Defense, Automobile, Sugar, Fertilizer, Cement, Paper, Power and Engineering Sector and provided good opportunity for the foundry men to interact with potential buyers of castings.

The major objective of the Pakistan Foundry Association (PFA) is to support the progress & development of Foundries in Pakistan by improving skills and up-grading technology. After 3rd IFCE 2010 some positive response has been seen by the government. In this regard National Productivity Organization - Ministry of Industries, Islamabad provided the services of a Foundry Expert Mr. Ram Chandra Narayan Bhome to visit certain foundries in Lahore for the improvement of this industry. His observations and technical advice for improving quality, productivity and cast reduction will provide positive result in the growth of light engineering sectors particularly SMEs.

In Pakistan, Foundry Industry's basic problem is scarcity of skilled man-power, which is resulting in low productivity and quality. PFA and TEVTA (Technical Education & Vocational Training Authority) Lahore, Govt. of Punjab is developing a training centre for un-skilled labour on the direction of Mian Shahbaz Sharif -Chief Minister Punjab.

Mr. Saeed A. Alvi-Chairman TEVTA has assured his full possible support and would be flexible to any model of cooperation with PFA as long as the requirement of Industry exists. I once again thank all those concerned with the foundry industry who participated in the 3rd IFCE and assure a dynamic business platform for their growth in future.

ContentsEvent Report of 3rd International FoundryCongress and Exhibition Lahore Organizedby Pakistan Foundry Association 2

44th Census of World Casting Production 9

The Potential of Casting in Pakistan 16

Case Study - Effect of Core Material onShrinkage Ravi Autos (pvt) Ltd. 22

Hardening & Nitriding of Dies & Mouldsin Vacuum Furnaces 24

59th Indian Foundry Congress &

International Foundry Exhibition 30

Event Report of3rd International Foundry

Congress and Exhibition LahoreOrganized by

Pakistan Foundry Association

Pakistan Foundry Association has organized 3rd International Foundry Congress & Exhibition (IFCE- 2010) on

December 1st & 2nd 2010 at Pearl Continental Hotel, Lahore Pakistan.

PFA is engaged for the up gradation of technology and skills development of foundry sector in Pakistan. The objective

of Pakistan Foundry Association is to provide a platform for the growth of Foundry Industry. Pakistan Foundry

Association has organized two such exhibitions in the year 2006 & 2008 before this Mega Event. The objective

behind these IFCEs is to correlate the foundry industries of Pakistan with the latest International Manufacturing

practices and to promote Trade, Commerce and manufacture of foundry products for the local & global markets.

Mian Muhammad Shahbaz Sharif - Chief Minister Punjab inaugurated 3rd International Foundry Congress &

Exhibition. The Punjab Chief Minister Mian Muhammad Shahbaz Sharif while addressing the Inaugural Ceremony of

3rd International Foundry Congress & Exhibition had emphasized there is a vast scope of development of

Engineering Sector. The Government of Punjab will provide all out facilities for this purpose including technical

courses in accordance with the market needs, introduced in TEVTA and other vocational Institutions.

The Chief Minister said the International Foundry Conference on the topic of “DUNYA HAMARI MANDI” would help

and provide a strong basis to engineering sector in Pakistan and every effort would be made to make Pakistan lead

other countries of the region in Engineering Industry. The Punjab Government is extending all out cooperation to

Pakistani & Foreign Industries for this purpose. The Industrialists associated with Pakistan Foundry Association are

playing an important role in saving foreign exchange by producing quality products. He appreciated the performance

of Mr. Sikandar Mustafa Khan - Chairman (Ex) Punjab Vocational training council, in this regard. “TEVTA and Punjab

Vocational Training council have been modernized and skilled work force according to market needs is being

produced” by his efforts he said.

The Chief Minister said he is ready to resolve all problems of the foundry industry and persons associated with the

sector should come to him for evolving an effective strategy. “Facilities within the scope of Punjab Government will

be provided and Federal Government will also be contacted regarding their problems” he promised.

Earlier Mr. Sikandar Mustafa Khan – President PFA also addressed the conference. He welcomed Mian Muhamamd

Shahbaz Sharif - Chief Minister Punjab and thanked him sparing his valuable time to inaugurate 3rd IFCE 2010. He

said PFA was established with the vision to develop Small & Medium Enterprises in Pakistan. In this regard he

especially thanked and appreciated SMEDA for the support in the development of Foundry Service Centre which will

2

SUPPORTERS

3rd International Foundry Congress/ Exhibition was organized with the major financial support by the following PFA

members and have been acknowledged with the mementos presented by Chief Minister Punjab Mian Muhamamd

Shahbaz Sharif.

1. Mr. Laeeq ud Din Ansari Director, M/s Millat Tractors (Pvt) Ltd

2. Mr. Shahid Ahmed Hakim CEO, M/s Bolan Castings (Pvt) Ltd

3. Mr. Ahmed Hassan CEO, M/s Chenab Engineering Works & Foundries (Pvt) Ltd

4. Mr. Adil J. Mansoor Chief Executive, M/s Excel Engineering (Pvt) Ltd

5. Mr. Masud Akhtar Managing Director, M/s KSB Pumps (Pvt) Ltd

6. Mr. Haroon Arshad Director, M/s Ravi Autos (Pvt) Ltd

7. Mr. Rizwan Qadri Director M/s, Qadri Group (Pvt) Ltd3

be a mile stone for the Foundry Industry. He said Pakistan Foundry Association was established in 2003 by few foundrymen with the vision to provide a platform for the growth of the foundry industry by improving skills and upgrading technology with the special emphasis on Small & Medium size foundries. SMEDA (Small & Medium Enterprises Development Authority) guided PFA through the stage of its inception.

Earlier the Chief Minister Inaugurated the Exhibition of Engineering Industry and appreciated the standard of casting equipment, Machinery tools and heavy duty machinery produced in Pakistan.

Mr. Shahid Ahmed Hakim – CEO Bolan Castings (Pvt) Ltd, Karachi thanked the Chief Guest, Senior Government Officials, Industrialist, Academician, Foundrymen and all participants for sparing their precious time to be here.

Mr. Sikandar Mustafa Khan presented a memento to the Chief Minister Mian Muhammad Shahbaz Sharif. In this event various Government Officials including Maj. Gen. M. Owais Mustafa –DG-MVRDE, Rear Admiral Muhammad Mushtaq – NUST, Mr. Aitazaz A. Niazi - CEO-EDB, Mr. M. Irfan Tarar –DG TDAP, Mr. Muhammad Ali -DG, TDAP, Mr. Anwar A. Khan –CEO SMEDA, Mr. Khawaj Muhammad Yousaf – CEO NPO, Mr. Razzaq Dawud – CEO Descon, Commercial Counselor from USA, Dr. Shujat Secretary Industry, Mr. Saeed Ahmed Alvi –Chairman TEVTA, Chairman Metallurgy Dept. of UET, Punjab University, GIKI and a large number of academicians, visitors from various industrial sectors and students from the Institutions have participated.

Maj. Gen. Muhammad Ovais Mustafa - D.G. MVRDE also visited the exhibition on day one. He was highly impressed while visiting stalls of local foundrymen and appreciated the skills development. He also chaired the first technical session of the 3rd IFCE - 2010.

According to survey report the exhibition was visited by around 3000 foundrymen, Engineers, Technical Managers, students etc from all walks of Industrial Sector. The major visitors were from Lahore, Gujranwala, Faisalabad, Sargodha, Rawalpindi/ Islamabad, Daska/Sialkot, Sheikhupoora, Karachi.

Few important visitors from foreign countries like Mr. Basar Oztopcular – Cukurova Kimya End. A.S, Turkey, Mr. Chavan Pruthviraj Ravindra, Mr. Shinde Sunil Shivajirao, Mr. Singh Subodh Rajan, Mr. Vinay kumar luthra – Gargi Huttenes-Albertus (Pvt) Ltd -India, Mr. Vikas – Director Marketing and Mr. Ashok Sharma -Engineer Megatherm-India and many more.

Those who could not participate due to political situation of Pakistan and certain restriction on travelling but have sent their best wishes and congratulations for the successful 3rd International Foundry Congress & Exhibition i.e. Mr. Andrew Turner – Secretary General World Foundry Organization (WFO), Libo Zhang –Senior Vice President & Secretary General –CFA, Mr. Tam Chi Ho –President Hongkong Diecasting, Mr. Tsedev MUNKHJARGAL- President, Mongolian Metallurgical Association – Mongolia, Mr. Subodh Panchal –Kastwel India, Mr. Vinod Kapoor-Gargi, Oxana Michel-Lativia, Dalian Dashan – China, Tarun Sangal, Benan Betik- Omega Foundry Machinery Ltd – UK.

Delegates

4

5

The 3rd IFCE 2010 also provided an opportunity to investors, machinery makers, foundry supply companies and service providers to showcase their products and services to their counterparts and potential customers and make alliances. The forum also provided a platform to eminent academicians and technologist from worldwide to come together and discuss advances and technical opportunities. PFA made the 3rd IFCE a SOURCING EVENT and Industrialist, Technical Managers and Purchase Managers from Sugar, Paper, Cement, Fertilizers, and Chemical participated in this mega event. Industrial delegates from England, Turkey, Czech Republic, China, India and other countries also participated in the congress and exhibition.

PFA organized special one to one meeting of Pakistan Foundrymen with their Managers to propose their local requirements and ways and means on technical grounds. Such exchange of views will benefit both the sectors and will save foreign exchange. Foundry sector in Pakistan has been experiencing an unprecedented growth from the last few years as the European & US Markets are focusing on this region of the World.

This mega event turned out to be an opportunity for the members of the casting industry to interact with international and domestic machinery and equipment manufacturers, suppliers and foundry technologists. Overall the 3rd IFCE has been regarded a successful and beneficiary event by the visitors & participants.

Scientific Session

Internationally renowned speakers discussed various foundry issues and shared their knowledge and experience through technical papers. They provided an insight into the global technology developments, future market prospects & raw materials. Pakistani speakers gave an insight about present growth and development in Pakistan foundry sector. The eminent speakers discussed innovative technologies, quality improvements, application of computer aided process in foundry industry. The objectives were disseminating knowledge among the foundrymen and benefit from the latest technology in the respective fields.

There were 6 technical session held in two days and eighteen technical papers were presented by the authors and presenters. Total papers received were around thirty but due to lack of time only eighteen presenters could deliver.

Mr. Abdul Ghaffar Soomro – Secretary Ministry of Industry & Production, Dr. Syed Aftab Ahmed

Managing Director - KRL Foundation Rawalpindi, Mr. Tariq Iqbal Puri – Chairman TDAP was unable to come due to their last moment official commitments.

6

Tea Break - From 11:15am to 11:30am

TECHNICAL SESSION # 2 on DAY TWO (DEC 02, 2010) SESSION CHAIRMAN: Mr. Anwar A. Khan - CEO SMEDA

9:50Effect of Heat Treatment on Micro Structure & Tensile Strength of ductile IronBy:Dr. M. Ashraf Sheikh- Rachna College of Engineering &Technology - Gujranwala

10:10Die Casting porosity mechanical properties By: Engr. Feroz Shah Wazir- University of Engineering & Technology- Peshawar

10:30Importance of Sand Grades in FoundryBy:Mr. Atif Makhdoom - Punjab University

11:00 Question & Answers / Comments by Chairman

THE SCIENTIFIC SESSION OF 3RD IFCE 2010

TECHNICAL SESSION # 1 ON DAY ONE (DEC 01, 2010)

SESSION CHAIRMAN: Maj. Gen. Muhammad Ovais Mustafa - D.G. MVRDE

Time Topic

11:30

Strategic Directions for Pakistan Foundry Industry By:

Mr. Imtiaz Ali Rastgar –

CEO Rastgar Engineering Company.

12:00

Development of Ferritic Grade SG Iron Utililizing

High Manganese Pig Iron

By: Mr. Munir Ahmed -

Consultant SMEDA

12:30

Concepts & Advantages of Heat Treatment

By:

Mr. Muhammad Yousaf Khan -

GM Matiari Sugar Mill

12:50

Comments by Chair / Question & Answers

Lunch & Prayer Break -

FROM 1:00pm -

2:00 pm

TECHNICAL SESSION # 2 on DAY ONE (DEC 01, 2010)

SESSION CHAIRMAN: Rear Admiral (R) Muhammad Mushtaq Pro Rector NUST

02:00

Foundry Production in Pakistan

By:

Dr. Khalid Akhtar -

SSME NUST Sector -

ISB

02:20

Gas Carburizing & Nitriding

By:

Mr. Ahsan Arshad -

Fornie Engineering

02:40Hardening & Nitriding of Dies and Moulds in Vacuum FurnaceBy: Mohammad Ali - Executive Heat Treatment, Karachi Tools Dies & Moulds Centre

3:00 Question & Answers / Comments by Chairman

Tea Break - From 3:15pm - 3:45pm

TECHNICAL SESSION # 3 on DAY ONE (DEC 01, 2010)

SESSION CHAIRMAN: Mr. Aitazaz A. Niazi - CEO EDB

3:45

Case Study -

Effect of Core Material on Shrinkage

By:

Mr. Pervaiz Mehmood -

GM -

Ravi Autos

4:15

Local Development of CNG Compressors

By: Mr. M. Asim-

Development Engg. Hyper Comp. Pvt. Ltd

4:45 Question & Answers / Comments by Chairman

Dinner & Cultural Show - 8:00 pm

TECHNICAL SESSION # 1 on DAY TWO (DEC 02, 2010)

SESSION CHAIRMAN: Mr. Saeed Ahmed Alvi - Chairman TEVTA

9:30Rejection Control in Cast Iron Foundry By: Engr. Allah Ditta - M/s Excel Engineering (Pvt) Ltd

7

11:30Design of Experiments & Casting Process Simulation By:Mr. Fatih Murat Akcin- M/s, Trojans & Magma Soft

12:00The Best practical Optimization of CO2 - Silicate Core ProcessBy:Mr. Sirajuddin Khan- DGM- M/s, Bolan Castings (Pvt) Ltd

12:30Aluminium & Aluminium AlloysBy:Mr. Javed Iraqi - GM Support Services- M/s, Atlas Engineering

12:50 Question & Answers / Comments by Chairman

Lunch & Prayer Break - FROM 1:00pm - 2:00 pm

Special Thanks

Exhibition

PFA highly appreciates and thanks for the services of Mr. Fahad Iqbal – Anchor person and Mr. Asim Qadri - Conference Coordinator for conducting two days Scientific Session of 3rd IFCE 2010.

There were around 80 stalls and 47 companies have showcased their products.Due to lack of space, late entrants could not be accommodated to provide them stalls. It is interesting to note that the whole exhibition had been sold out. The Exhibitors names are mentioned below:-

A.N Engineering Industries (Pvt) Ltd Al-Zarooni Al-Khawja Enterpirses Atlas Copco Pakistan (Pvt) Ltd

Al-Shafi Steels (Pvt.) Ltd. ( Ittefaq Steels)

Bolan Castings

(Pvt) Limited Chenab Engineering Works &Foundries (Pvt) Ltd

EXCEL Engineering (Pvt) Ltd

E

-

TECH

Electro Heat (Pvt) Ltd.Eehab Engineering Company Pvt

ltd

Electrotherm India Ltd

Gohar Industries (Regd)

Infinity Engineering (Pvt) L td

Ideal

Foundries & Engineering

Works

Ijaz Brothers (Pvt) Ltd

Jameh Engineering (Pvt) Ltd

K.M. Enterprises

(Novacast)

KSB Pumps Company (Pvt) LtdKamraj Enterprises (Pvt) Ltd

KB Enterprises

Mosh Pakistan

Madina Group of Industries

Matchless Engineering (Pvt) Ltd

Millat Group of Companies

Marriala Consultants

New Era Industries (SMC-Pvt) Ltd

Paktherm (Pvt) Ltd

PSQCA –

Technical services centre

Pakistan Engineering Company Ltd

Quality Casting (Pvt) LtdQADBros Engineering (Pvt) Ltd

Ravi Spherocast (Pvt) Ltd

Ravi Autos (Pvt) Ltd.Rastgar

Engineering Co (Pvt) Ltd.

Sun Metal Industries

Supraa Steel (Pvt) LtdSajid Brothers Engineering

Industries

Spectra Corporation

S.G.I. Foundries

Super Tech Industries (Pvt.) Ltd

Small and Medium Enterprises Development Authority (SMEDA)

Steel Casting &

Engineering Works

Transfopower Industries (Pvt) Ltd Trojans We Brothers Scientific Pvt Ltd

Western technologies (Pvt) Ltd Zaid Products (Pvt) Ltd

Total around 80 Stalls of 47 different companies

Media Participation

Magazines: -

Awards

Volunteers Role for 3rd IFCE 2010

Gala Dinner & Musical Evening

3rd IFCE 2010 inaugural ceremony News were flashed and interviews displayed on various TV Channels like GEO, Sama, Express TV, Aaj Tv, PTV, Dawn, Dunya TV etc.The following daily News Papers gave a wide coverage of 3rd IFCE 2010:- Jang News, The Nation, The News, Business Recorder, Jang News, Pakistan, Express, Ausaaf, Al- Sharq, Khabrain, Din, Asaas, Jinnah & Awaaz News paper etc.

International Foundry Magazine: The Foundry Plannet, Foundry Trade Journal, Foundry Gate, Casting Area, Alu Scout placed the News of 3rd IFCE on their websites under the heading of events from the last so many months .

Local Industrial Magazines: Industrial Bulletin by Engineering Development Board (EDB), Lahore Chamber News, The Engineering Horizon Magazine, Auto Mark Magazine & Build Plus Magazine advertised our news as an advertisement and published the report of the Event.

- Mr. Sikandar Mustafa Khan visited each stalls and thanked for their participation for successful organization of 3rd IFCE and presented Certificates and Souvenir (Conference Bag).

- Mr. Abdul Rashid – Secretary PFA services were recognized for his tiring efforts for the successful organization of 3rd IFCE 2010 by Sikandar Mustafa Khan - President & Mr. Asim Qadri – Secretary General PFA. Both of them highly appreciated his efforts and were also acclaimed by the audience.

The worthy volunteers who put their efforts to make 3rd IFCE a successful event were acknowledged by presenting a Shield. They are Mr. Munir Ahmed – Chairman, Mr. Asim Qadri- General Secretary PFA, Mr. Irfan Ahmed Qureshi – Joint Secretary, Mr. Iqbal Khalid – Senior Executive Member, Mr. Abdul Rashid – Secretary PFA, Mr. Zaid Bin Maqbool, Mr. Waqas Gohar, Mr. Munir Ahmed, Mr. Ashraf Sheikh, Mr. Faisal Saeed Qureshi, Mr. Ghazanfer Nazir Malik, Mr. Larry Heatherly, Mr. Waqas Haroon and Mr. Abdul Jabbar.

PFA arranged Gala Dinner & Musical Program in the honour of their guests 3rd IFCE 2010 at Kohinoor Hall –Pear Continental Hotel Lahore. Madam Shabnam Majeed –vocalist entertained the audience with her special Songs and Ghazals.

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Want to compare 2009’sproduction to previous years?Visit www.moderncasting.comfor past census results.

Worldwide casting shipments in 2009 fell to 80,343,048 tons, down 14% from 2008, according to this year’s

MODERN CASTING Census of World Casting Production. Of the 34 countries participating in the production survey

this year, only five reported growth—China, India, Korea, Portugal and South Africa. The average percentage

decrease in shipments for the remaining countries with declining production was 30%. As a result, production per

plant decreased, as well. Germany still has the most production per plant, but it fell from 9,639 tons per metalcasting

company in 2008 to 6,481 tons in 2009.

China’s production improved from 1,117 tons to 1,357 tons per plant as shipment volume increased and the number

of casting facilities decreased. Seven of the top-10 casting-producing nations shifted up or down in the rankings in

2009, reflecting the fluctuating markets during the recession. Brazil, which had been one of two top-10 countries to

show growth in 2008, experienced a 31.5% decrease in shipments from 2008 to 2009, the biggest drop of any top-10

nation during that time period. India was the fastest growing top-10 nation, increasing its casting tonnage by 9%. The

top 10 nations produced a total of 70,476,338 tons, 88% of the global total.

The year 2009 marked the fourth year in a row the U.S. has reported a reduction of casting volume. It was the first year it has been surpassed in production (by 35,000 tons) by India, which became the second-largest casting

producer by volume. The data reported in the 44th Census of World Casting Production is supplied by each nation’s

metalcasting association or similar representative. Countries that did not participate this year were Denmark, The

Netherlands and Thailand. These countries remain listed according to the last year they participated. New to the list are Bosnia and Herzegovina, Mongolia and Serbia. MC

Production Per Plant

World Casting Production by Metal

The average production per metalcasting plant for the top-10 nations decreased across the board, likely due to plants

operating at lower capacity during the 2009 recession. China

and Korea, which showed increases in casting shipments

from 2008 to 2009, improved their productivity.

While gray iron continues to make up the largest piece of the

global production pie, its sliceis growing smaller. Since 1999,

gray iron production has increased 9.3%. Compare that with

a 39.6% increase in ductile iron production, 50% growth in

steel production, and a 41.1% increase in nonferrous

production.

Italy: 1,488

France: 3,783

Korea: 2,454

Brazil: 1,725

Germany: 6,481

Russia: 3,111

Japan: 2,584

U.S: 3,596

India: 1,618

China: 1,357

0 1 2 3 4 5 6 7 8Thousands of Tons

Top

10 C

astin

g C

ount

ries

Nonferrous13.6 million tons17%

Gray Iron38.16 million tons47%

Ductile Iron19.4 million tons224%

Steel9 million tons12%

MODERN CASTING / December 2010

44th Census of WorldCasting ProductionThe global casting market experienced a marked contractionin 2009, with overall shipments decreasing 14% from 2008.

A MODERN CASTING Staff Report

9

Country

Austria

Belgium

Bosnia Herzegovina

Brazil

Canada

China

Croatia

CzechRepublic

Denmark E

Finland

France

Germany

Hungary

India

Italy

Japan

Korea

Mexico

Mongolia

NetherlandsH

Norway

Poland

Portugal

Romania

Russia

Serbia

Slovenia

SouthAfrica

Spain

Sweden

Switzerland

Taiwan

ThailandJ

Turkey

Ukraine

UnitedKingdom

UnitedStates

TOTALS

Note: All data given in metric tonsF) includes zinc G) lead casting H) 2004 data I) all ferrus J) 2006 data

Gray Iron Ductile Malleable Steel Cu-Base Aluminum Mg Zinc TOTAL

29,200 89,700A na 19,800 2,203 87,698 4,676 10,191 na 243,468

49,100 B 500A na 28,100 na 1,582C na 530 na 78,812

1,100 na 3,826 na 3,176D na na na 16,669

1,365,030 525,971 26,850 166,382 12,075 194,569 3,233 2,806 na 2,296,916

458,850 E na na 111,720E 17,656E 146,879 na na na 735,105

17,000,000 8,700,000 600,000 4,800,000 600,000 3,350,000C na na 250,000 F 35,300,000

22,107 17,375 na 1,313 459 11,652 na 230 661G 53,797

138,838 40,678 1,881 52,392 888 34,772C na 1,368 144 270,970

32,367 48,020 na na 1,433 na na 6 5,778 D 87,604

28,041 31,363A na 9,413 3,052 3,612 na 260 na 75,741

562,000 869,000A na 59,500 18,818 205,924 na 19,513 1,949 1,736,704

1,806,480 1,191,786 31,273 182,435 76,720 540,444 19,859 51,193 1,475 3,901,665

25,834 15,221 11 5,695 1,442 80,10 na 3,738 262 132,304

5,050,000 800,000 60,200 880,000 na 653,000D na na na 7,443,200

566,068 372,449A na 65,283 14,386 549,400 6,700 49,000 45,516 1,668,802

1,653,901 1,364,644 37,235 198,248 75,284 1,025,507 6,280 20,563 4,336 4,385,998

1,020,600 607,600 38,500 153,500 24,500 279,100 na na 11,200CF 2,135,000

693,975 53,010 na 70,815 126,530 539,990 98 906 na 1,485,324

2,000 120 100 12,000 60 180 na na 240 14,700

78,241 6,209 438 na na na na na na 84,888

15,200 48,400A na 2,700 2,177 4,058 na na na 72,535

570,000 I na na na na 200,000D na na na 770,000

30,995 60,165A na 8,803 10,800 15,800 na 480 na 127,043

29,485 1,471 712 22,955 1,814 31,163 1,750 535 9 G 89,894

1,740,000 1,200,000 60,000 700,000 90,000 340,000 35,000 15,000 20,000 4,200,000

43,150 2,320 1,460 25,040 995 1,420 na 500 14,260 89,145

74,000 14,900A na 27,900 2,976 18,144 495 2,079 na 140,494

68,832 114,276 147,235 17,220 47,364 na 2,730 na 493,222

274,000 461,300A na 65,200 6,791 86,212 na 8,084 491 902,078

113,300 27,700 na 15,300 8,400 24,600 1,300 4,000 na 194,600

17,600 31,000A na 1,806 1,807 14,613 na 1,308 na 68,134

343,854 175,902 na 50,849 33,166 230,059 5,159 74,629 1,065 914,683

70,000 30,000 30,000 28,600 28,600 100,000 na 16,900 na 304,100

456,000 352,000 2,000 98,000 12,500 96,500 na 13,500 na 1,030,500

640,000 40,000 na 275,000 na 45,000D na na na 1,000,000

102,000 137,000A na 56,000 8,000 78,000 2,000 6,200 700 389,900

2,409,483 2,553,725 35,380 686,739 178,715 1,191,1345 66,224 166,922 119,748 7,408,069

37,615,831 19,939,470 1,040,316 9,032,549 1,379,467 10,237,431 152,774 473,170 472,056 80,343,064

A) includes malleable iron B) includes ductile Iron C) includes mg D) all nonferrous E) 2008 data

8,567

OOtthheerrNon-Fe

95,565

2009 World Casting Census

New to the List

A few new countries have been added to this year’s census of casting producers and another has been updated after

seven years of incomplete data. Ukraine: Before this year, the most recent production data from Ukraine dated to

2002, when the country was producing 974,170 tons of castings a year. Not much has changed. The Foundry

Association of Ukraine reports the country produced about 1 million tons of castings in 2009. Ferrous casting makes

up the lion’s share of production (95.5%), but nonferrous casting has improved 42.9% since 2002. Serbia: For many

years, this country has been in turmoil, with much of the casting activity shut down or severely hampered.

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From 1990 through 1999, its economy was cut in half. Since then, Serbia has been making up ground. In 2008, the

Serbian Foundrymen Society was formed. The country’s casting industry is 81% ferrous and 19% nonferrous by

tonnage produced. Production per plant is 2,345 tons. Mongolia: More than two-thirds of all of Mongolia’s exports

go to China, its neighbor to the south. Its largest casting market is steel, which makes up 81.6% of total production.

With the exception of a few nations, the global casting industry reported a dip in production in 2009. But some

countries fared worse than others.

Russia: From 2007 to 2009, Russia’s production decreased by 46.2%, from 7.8 million tons to 4.2 million tons. The

third largest casting producing nation in 2007, Russia has since fallen behind India and Japan. It saw a reduction of

300 metalcasting facilities in 2009.

China

Mill

ion

of

Ton

s

India U.S Japan Russia0

0

10

15

20

Grey Iron Ductile Iron

Gray Iron vs. Ductile Iron

Globally, 65% of iron castings

produced are in gray iron, compared

to 35% produced in ductile

iron. But this type of disparity is not

present in every country. Among the

top five casting

nations, the U.S. produces more

ductile iron castings than gray iron,

while Russia and Japan

show closer gaps between the two

materials than do China and India.

Finland:

Czech Republic:

In one year, Finland’s casting production was

cut in half, from 152,888 tons to 75,741 tons. Casting

production value decreased 46% to $350 million. Zero

metalcasting facilities closed, according to the European

Foundry Assocation, but employment in the industry

constricted by 700— 15.7% of the workforce.

The nation’s production fell 49.5% from

536,789 tons to 270,970 tons. Productivity dropped

from 2,684 tons/plant to 1,505 tons/plant. MC

Metalcasting Plants by NationCountry Iron Steel Nonfferrous Total

Austria 29 4 39 72Belgium 16 7 8 31Bosnia Herzegovina 5 2 4 11Brazil 552 191 588 1,331Canada A 41 29 115 185China 17,000 4,700 4,300 26,000Croatia 15 3 24 42CzechRepublic 84 34 62 180Denmark A 7 0 10 17Finland 14 6 16 36France 103 37 319 459Ger\bany 205 53 344 602Hunary 62 31 97 190India - - - 4,600Italy 157 44 920 1,121Japan 456 75 1,166 1,697Korea 508 142 223 873Mexico 181 162 350 647Mongolia 24 15 3 42NetherlandsB 16 0 5 21Norway 8 3 11 22Poland C 185 0 245 430Portugal 47 6 39 92Romania 53 45 71 169Russia - - - 1,350Serbia 14 8 16 38Slovenia 8 3 16 27SouthAfrica 88 51 117 256Spain 60 32 50 142Sweden 32 13 73 118Switzerland 18 4 43 65Taiwan C 478 40 330 848Thailand D 230 26 220 476Turkey 741 72 433 1,246Ukraine E 400 233 437 960UnitedKingdom 230* - 220 450UnitedStates 659 416 985 2,060

*Includes iron and steel facilities. A) 2008 data B) 2004 data C) 2007 data D) 2006 data E) 2002 data

11

I\f\bia: 1,7

Chi\fa: 1,202

Top-10 Casting Producers

35.3 million tonsGray iron 17 million tonsDuctile iron 8.7 million tonsSteel 4.8 million tonsNonferrous 4.2 million tons

1. China (1)

2. India (4)

3. U.S. (2)

4. Japan (6)

5. Russia (3)

6. Germany (5)

7. Brazil (7)

8. Korea (10)

9. France (9)

7.4 million tons

10. Italy (8)

Gray iron 5.05 million tonsDuctile iron 800,000 tonsSteel 900,000 tonsNonferrous 650,000 tons

7.4 million tonsGray iron 2.4 million tonsDuctile iron 2.6 million tonsSteel 690,000 tonsNonferrous 1.7 million tons

4.4 million tonsGray iron 1.7 million tonsDuctile iron 1.4 million tonsSteel 200,000 tonsNonferrous 1.1 million tons

3.9 million tonsGray iron 1. million tonsDuctile iron 1.2 million tonsSteel 180,000 tonsNonferrous 690,000 tons

4.2 million tonsGray iron 1.7 million tonsDuctile iron 1.2 million tonsSteel 700,000 tonsNonferrous 500,000 tons

2.3million tons

million tons

All iron 1.9 million tonsSteel 170,000 tonsNonferrous 210,000 tons

2.1 million tonsGray iron 1 million tonsDuctile iron 610,000 tonsSteel 150,000 tonsNonferrous 310,000 tons

1.74 milli\bn t\bGray iron 560,000 tonsDuctile iron 870,000 tons Steel 60,000 tonsNonferrous 250,000 tons

1.67 million tonsGray iron 570,000 tons Ductile iron 370,000 tonsSteel 65,000 tonsNonferrous 665,000 tons

(Last year’s rank in

Regional ProductionEurope’s total production fell 31.5% since 2008; North America’s production dropped 28.5%. North and Southeast Asia fared best, with India, China and Korea showing gains in 2009.

India 7.4 million tons

China35.3 million tons

Japan4.4 million tons

Russia4.2 million tons

Europe12 million tons

North America9.6 million tons

Brazil2.3 million tons

12

Visit of Mr. Ram Chandra Narayan – Foundry Expert

Pakistan Foundry Association successfully organized

3rd International Foundry Congress & Exhibition on

Dec 01/02-2010. The success of 3rd IFCE was realized

by various government departments and approached

PFA to extend their favour for the development of

foundry industry.

In this regards a meeting was arranged between Mr. Sikandar Mustafa Khan – President PFA, Mr. Asim

Qadri – Secretary General and the Executive

Committee of Pakistan Foundry Association with Mr. Khawaja Muhammad Yousaf – CEO, National Productivity Organization (NPO) - Ministry of Industries, Islamabad, Mr. Ejaz Rasul Chawdhry -GM

and their Expert Team. They offered the services of Mr. Ram Chandra Narayan Bhome an Engineering

Professional with a great experience of 37 years who

will be visiting Pakistan for about 2 weeks.

Mr. Ramchandra Narayan visit was planned from Jan

24 to Feb 05, 2011 with a Tentative Schedule to fulfill

the needs of our foundry members industries for

Technical Guidance, Efficiency Enhancements, Process Engineering and Cast control.

Mr. Ram Chandra visited 12 foundries in Lahore and

made certain observations in different foundries and

suggested remedial actions on the spot. He spent

sufficient time for their guidance in each foundry as

desired by the foundry members.

According to PFA Plan, Mr. Ram Chandra Narayan

Bhome had to visit foundries in Gujranwala and

Faisalabad also but due to limited visa facility he could

visit foundries in Lahore only.

A seminar for the training of technical managers was

organized for two days in PITAC – Lahore. It was a joint

venture of NPO & PITAC on the foundry production

system.

The purpose of this workshop was to create

awareness and understanding to improve and

enhance production efficiency according to his observations during his visits to foundries.

Pakistan Foundry Association is obliged by the visit of

Mr. Ram Chandra Narayan and believes his visit will

definitely benefit our members.

Mr. Sikandar Mustafa Khan – President PFA thanked

him once again in a get together at High Tea arranged

in his honour for his visit to foundries in Lahore and

observations along with the suggested remedial

actions. These will benefit in improving quality of our

production. He said, your suggestions for the

improvement of foundries in Pakistan are quite

valuable and we are thinking on the same lines as

proposed.

It will be my pleasure to welcome you again in Pakistan

for the assistance & cooperation of Foundry Industry. I will suggest there should be two way communications

between you and your visited foundries during your

stay for continued growth.

On returning home he conveyed his satisfaction and

thanked Mr. Sikandar Mustafa Khan, members of PFA

and Mr. Abdul Rashid – Secretary PFA for the services

provided to him during his comfortable stay, “He

remarked I never felt away from home”. He admired

the enthusiasm shown by PFA Members to learn new

technologies and to improve the performance of their

individual foundry.

13

Courtesy: National Productivity organization (NPO)

14

Mohammad Sajjad PresidentPh: 042 36167117 / 37722750Cell: 00923334257790email: blackstonesajjad@yahoo.com

Prepared by: Ahmad Hassan (CEO Chenab Engineering Works & Foundries) Special thanks to Munir Ahmed (Consultant CFC)Presented by Ms. Nadia Hassan

· Overview of Casting Industry· Comparison of Pakistan with China· Comparison of Pakistan with India · Feasibility of achieving targeted production ( in comparison with India)· Standard model and calculation for payback period· Benefits from exporting to foreign Market· Conclusion

• The foundry engineering is the mother of all engineering and its contribution is noteworthy towards the development of any country.

• There are 2 types of Casting: i- Ferrous ii- Non-Ferrous

• According to the 43rd census of world casting production 2008: Total production of the world is 93.4 million metric ton Production of Asia is 58.9 million metric ton (63.11% of the world's production)

Structure of the Report

Overview of Casting Industry

Sr. No Country Production (Million ton)

% production

1 33.5

35.8

2 10.8

11.5

3 7.8

8.4

4 6.8

7.3

5 5.8

6.2

6 5.7

6.1

7 3.4

3.6

8 2.6

2.8

9 2.4

2.6

10

China

USA

Russia

India

Germany

Japan

Brazil

Italy

France

Korea 2.1

2.2

Sr. No

CountryProduction

(Million ton) %age

Production

No. of

plants

1 China

33.5

35.8

3000

2

India

6.8

7.32

4700

3

Turkey

1.2

1.3

1246

4

Japan

5.6

6.0

1702

5

Thailand 0.3

0.3

476

6

Taiwan 1.4

1.5

848

7

Korea

2.0

2.1

873

8

Pakistan 0.35

0.37

250

Top 10 Casting Producers of the worldProminent Countries in Asia which majoritycontribute towards casting:

One major question that arises from this overview is:

“ If countries like India and China can prosper so much then why can not a country (Pakistan) enriched with ample

resources flourish? “Few of the problems facing India and China are similar to that of Pakistan:

- India for example is currently facing electricity crises but they have intelligently manage it to cope with

their production targets. Why not Pakistan follow the same steps????

China for example, with the help of coal gasification and washing plants, has successfully used their coal

“The Potential of Casting in Pakistan”

16

reserves for power generation. Then why can not Pakistan use these cheap plants for upgrading the available coal

reserves for power generation????? - Thar coal reserves are the largest coal reserves in the world. The only problem is that coal need washing

(sulphur 6 -10 %).Otherwise rest of the specifications e.g. caloric value, ash content and fixed carbon etc

are within limit.

Comparison of Pakistan and China with respect to respective countries' prices and potential in casting.Comparison of Pakistan and India with respect to the countries potential and resources availability.

According to year 2008 figures:

- Population: 1.3 Billions - Production: 33.5 Million tons

- Population: 0.18 Billions - Production: 0.35 Million tons

The population of China is almost 7.2 times more than that of Pakistan. Following this the production of Pakistan

should be 4.65 million tons which at present is only 0.35 million tons. This means that Pakistan's production is 4.3

million tons less than the expected value.

• Comparison of prices :• Price break up of a standard firm casting in Pakistan • Total cost on raw material (less foundry return) per kg = Rs 47.14• Total cost of other materials per kg = Rs 12.65• Total cost of fuel and power per kg = Rs 14.25• Total cost of molding, melting, all other felting, painting, short blasting etc per kg = Rs. 8.41 • Bank Charges per kg = Rs 1.25 • Non productive expenses = Rs 6• Total COST PRICE per kg = Rs 89.7 • With a profit margin of 10% - SELLING PRICE = Rs 98.7 Whereas , casting prices in China vary within the following range :

Rs 104 ≒ Price per kg ≒ Rs 130 Where Rs 104 refers to a typical low cost firm's price and 130 refers to a typical high cost firm's price.

Likely reasons for such a price edge can be excess supply of cheap labor, availability of natural resources and likewise other related factors.

However, comparing the production scale of Pakistan with China will be inappropriate given the size of the economies and development scale. On the other hand comparison with India will make more sense as Pakistan shares a lot of common features with this neighboring country.

• According to Modern Casting December 2009:“India's metal casting industry is poised to become one of the top-three casting producing nations in the world. The key is establishing the infrastructure to support it.”

Comparison of Pakistan with other Asian countries

Comparison of Pakistan with China

China:

Pakistan:

Analysis of the figures:

Comparison of prices clearly shows that Pakistan has a price edge over China.

Comparison of Pakistan with India

17

• The growth in casting production of India is remarkable since year 2002. India benefits from: i) low labor costs, ii) large population with a strong domestic demand, iii) financially strong companies with revenues to invest in metal casting. iv) Furthermore India's economic environment is suitable for metal casting. v) Construction costs for new casting facilities, as well as time to complete construction and permitting are low. vi) Health and safety compliance requirements for molding binders are nearly non-existent and tooling costs are significantly lower than in developed countries.

i) Even though tooling costs are lower but tooling quality is still lagging ii) lack of sufficient infrastructure iii) consumable costs are higher than developed countries iv) energy supply problems, especially a reliable supply of electricity v) attracting and maintaining an enthusiastic, younger force is a challenge in India.

• Hence we can see that most of the advantages enjoyed by India as well as problems faced by the Indian economy are quite similar to our Pakistani economy. Therefore comparing our economy with the Indian economy and setting it as our benchmark will be wiser rather than comparing with economies like China.

• According to year 2008 figures:

India: - Population: 1.14 Billions - Production: 6.8 Million Tons

Pakistan: - Population: 0.18 Billions - Production: 0.35 Million Tons

• Analysis of the figures: The population of India is almost 6.3 times Pakistan's population. Following that Pakistan's production

should be 1.07 Million Tons. At present it is 0.35 million tons which is 0.73 million tons less than the expected value.

• As mentioned earlier too, Pakistan's casting is cheaper than both India and China. Hence Pakistan should make efforts to utilize its potential to the maximum and increase its production. Increasing production by 0.73 million tons might not currently be possible due to the energy and policy constraints in Pakistan but a step forward will not hurt the country's development plan.

• Assume the target is to increase casting production by 0.73 million ton• 1 ton = 1000 kg• Cost price = Rs 89.7/kg• Selling Price = Rs Rs 98.7/kg• Gross Profit = Rs 9/kg• Taxes and other miscellaneous charges = Rs 3/kg• Net Profit = Rs 6/kg

• Hurdles faced by india:

Feasibility of achieving targeted production ( in comparison with India)

18

• Given the net profit per kg = Rs 6 , if Pakistan increases its production by 0.73 million tons. The additional profit earned by Pakistan will be ::

Ð = 0.73 million tons x 6000/ton = Rs 4380 million ( minimum profit)

Graph ( price & profit) - Feasibility of achieving targeted production ( in comparison with India)

1- Utility expenses 2- High fluctuation in the price of imported raw material

1- Government should invest in exploring iron ore.2- Use of wind energy and hydro energy etc in power generation3- Coal gasification and washing plants for power generation4- Proper government plan and cooperation with foundry engineering

None of the remedies suggested are currently being implemented but through asuccessfulimplementation of these remedies, an additional target of 0.73 million ton ( casting production) can be achieved in next couple of years.

- Figure of 0.73 million tons is not a huge threat to India or China given their casting production, but Pakistan can gain a lot through this additional production - Through this additional production Pakistan can not only meet the additional demand of domestic economy ( currently imported) but can even export the surplus production.

Feasibility of achieving targeted production ( in comparison with India)

• Major Constraints to achieve the targeted production :

• Remedies:

• Current Scenario :

• Potential gains from additional Production of 0.73 million tons in future:

19

Standard Model

• Assume a plant has a yearly production = 12000 tons• Net Profit/ ton (calculated before) = 6000/ton • Total Net Yearly Profit = (12000 x 6000) = Rs 72 millions• Assume Fixed Cost investment = 40 million (Land) + 100 million (machinery) + 30 million ( utilities) = Rs 200

millions• Assume working capital = Rs 100 million• Assume interest payment = Rs 60 million

Total investment = Rs 360 millions

• Pay back Period = (Total Investment) / (Total net yearly profit)• Therefore payback period with casting production = 12000 ton and minimum profit margin = 6000/ton will

be = Rs 280m / Rs 84m = 5 years.

Model (graph) – payback period with yearly production of 12000 tons

0

1

2

3

4

5

6

0

20

40

60

80

100

120

140

1 2 3 4 5 6 7Playback period in years Price

0.0

0.5

1.0

1.5

2.0

2.5

3.0

0

20

40

60

80

100

120

140

1 2 3 4 5 6 7Playback period in years Price

Model (graph) – payback period with yearly production of 24000 tons

ModelAnalysis of graphs:

Benefits from exporting to foreign market

Above graphs clearly shows that when the firms will be producing high value casting products or selling low value casting products at a high price price per ton will increase profits will increase payback period will decrease !

Comparative advantage through low relative price as compared to India and China attracting wider consumer baseCheap product in the international market due to depreciation of the Pakistani currency. e.g. exchange rate of Pakistan with china increased from 1Yuan = Rs 7.8 (year 2007) to 1 Yuan = Rs 13 (year 2010)· Inflow of technology· Increase consumer base through international market· Inflow of Foreign currency increase foreign reserves · Positive effect on the Balance of payment

Export demand increases Total domestic production increases Average Cost per unit will fall through Economies of scale Net profit/ton increases!Export demand increases Total domestic production increases domestic employment increases disposable income increases Aggregate demand for goods and services will increase Real GDP increase Economic growth and overall standard of living of the economy will increase!

20

Conclusion

It is fair to conclude that Pakistan which is rich in factors of production e.g. land , labour , natural resources and entrepreneur skills , should efficiently utilize these resources to meet at least reasonable future targets.In the coming future major production is shifting from USA and European countries to China and India. Then why not Pakistan (which is the part of the same subcontinent) increases its % production and be one of the prominent producers supplying to the foreign markets????? • Pakistan is a home of several bright people. I believe that we have radiant minds sitting amongst us today that can not only help in the nourishment of the industry, they can also enrich our minds with their brilliant ideas. This will help country develop successful future strategies and their implementation will help country efficiently compete in the international market at all standards.

I also believe that the youth of the nation has a lot to offer. A concoction of our experiences with their minds can definitely prove to be beneficial for the burgeon of the casting industry.

Omega foundry machinery was formed 1984, following

management buy out from parent company Baker Perkins

who had been manufacturing foundry equipment since 1957.

The company has continued to specialize in the manufacture

of equipment for, Chemically Bonded sand or No bake

process. Their productions are Sand mixing, Mould Handling,

sand reclamation, core making, Trunkey projects and Ancillary

Items i.e. Sand driers, Sand heaters, Dust extractor, batch

mixer, Mould driers etc.

Mr. Benan Betik – Area Sales Manager was expected to

participate in 3rd International Foundry Congress & Exhibition

- 2010 but due to visa issues he could not join us. Recently he

managed to come to Pakistan and visited certain important

foundries for the introduction of Omega Machinery Products.

He was also invited by Mr. Faheem A. Malik – Project Director, PCSIR Daska for a presentation on his projects. Mr. Benan Betik

had a very thought provoking presentation on the above

mentioned productions. The participants were from major

foundries in Lahore & Gujranwala i.e. Qadbros, Ravi Autos,

Quality Casting, Excel, Chicago Metals, Supra Steel, Asian

trading corporation, International Fabrication . The

participants were highly impressed from his presentation.

I am sure Omega Machinery products will be available in

Pakistan very soon and PFA wish great success for Omega

Foundry Machinery.

Welcome Omega in Pakistan

21

Case Study - Effect of Core Material on ShrinkageRavi Autos (pvt) Ltd.

Part Name

GradeArm Hydraulic Lift Ram

BS 3100 Grade A3C:0.40 – 0.45 % MaxMn:0.70 % Min Hardness: HB 163 ~ 207 (Prior to Induction Hardening)

Molding Process

Core Material

Melting

Sodium Silicate sand process used for Molding

Sodium Silicate Sand Process Cores

Melting is done on high frequency induction furnacePouring temperature range: 1600°C - 1620°C

Problem-Shrinkage:

Problem-Shrinkage:

Shrinkage occurred inside thick portion of casting

Simulation done with little improvementBetter results but Pattern also needed modificationAs suggested Chill was also tried but production rate was low due to placing of chill

Pattern & Casting

22

Problem-Shrinkage:

Problem-Shrinkage:During this period due to ro ugh surface finish inthe hole the machining section was complaining.

We were already working on the Die of Corefor “Shell Core Sand”. When started using ShellCore it was observed that the riser had muchmore shrinkage at the top then the usual practice.Pieces were sectioned to see if it has contributedto shrinkage. Surprisingly the shrinkage waseliminated.

Cross-Section of Arm Hyd. Lift Ram with no Shrinkage

Comparison of Cores

It gave us motivation & encouragement to do more research on Shell Core Sand.More samples were casted using Shell Cores and their cross-section exposed elimination of shrinkage problem.

CO2 & Shell Cores

Coclusion

Sodium Silicate Cores exhibit Endothermic Reaction after pouring.

Shell Cores show Exothermic Reaction when contact with hot metal.

Shell Core Sand, beside shrinkage elimination, are very easy to remove & give good surface finish.

The Exothermic Reaction of Resin Coated Sand Cores, when contact with hot metal, helps keeping themetal flowing from riser into the casting and hence eliminates shrinkage.

23

Hardening & Nitriding of Dies & Moulds in Vacuum FurnacesEngr. Muhammad Ali - B.E (Metallurgy & Materials), M.E (Material Science & Technology),Karachi Tools, Dies & Moulds Centre - Karachi

Introduction:Vacuum Heat treatment is one of the modern heat treatment technologies which helps to determine the right process & right cycle to meet the metallurgical requirements in hardening and nitriding of dies & moulds through precise temperature and atmospheric control. Customers specifications are achieved with minimal distortion and bright, scale free results in the finished products.

Introduction:

Advantage of vacuum heat treatment process:

Processes Facility:

Vacuum Heat treatment is one of the modern heat treatment technologies which helps to determine the right process & right cycle to meet the metallurgical requirements in hardening and nitriding of dies & moulds through precise temperature and atmospheric control. Customers specifications are achieved with minimal distortion and bright, scale free results in the finished products.

Heating metals to high temperatures normally causes rapid oxidation, which is undesirable. Vacuum heat treatment removes the oxygen and prevents this from happening.The need for precise control of temperature and time, as well as the process environmental chemistry, has led to the application of computerized control systems for most types of modern vacuum furnaces. Following are some of the advantages of this process:

· No decarburization· No oxidation of components – bright surfaces· High temperature uniformity – low distortion· Full automation of heat treatment process· Environment friendly· No heat radiation to atmosphere· Low contamination of the product by oxygen and other gases· Quick cooling (quenching) of product· Computer control to ensure batch to batch consistency· Precise control of case depth, microstructure & hardness

The processes which can be carried out by vacuum heat treatment furnaces are:· Annealing, · Stress relieving,

Vacuum hardening & nitriding furnaces Vacuum Hardening Furnace

24

· Hardening, · Tempering · NitridingDifferent ranges of temperatures for carrying out above processes are carefully determined with the help of TTT and Iron-Carbon Diagrams as in figure number 3 and 4.

Tool Steels suitable for heat treatment in vacuum furnaces:

Vacuum Heat Treatment Process:

Hardening Process:

· Hot Work Tool Steels like H-11 & H-13· Cold Work Tool Steel Like D2 & D3· Moly High Speed Steels

Heat treatment of hot & cold work tool steels in vacuum furnaces is today state of the art technology with

fully automatic process which employs latest HMI system (human machine interface).All parameters like

temperature of the surface and core of heating stock, pressure levels of nitrogen/ammonia gas and

information on various levels of vacuum etc are displayed continuously on furnaces screen and can be

reset as per behavior of the charge components.

Like other processes, this process also involves heating, holding & cooling.

However in other processes during heating up & cooling, temperature

difference occurs in surface & core of the component. This temperature

difference in other processes can not be avoided and is reason for

component distortion due to residual stresses. This component distortion

can be reduced by CONTROLLED step by step heating and cooling in vacuum

heat treatment furnaces. Desired microstructure & ultimate hardness is

achieved by a predetermined programme of phase transformation which is

the specialty of vacuum heat treatment process.

Normally oxidation occurs on the part's surface when exposed to the atmosphere (air). This results in

costly and time-consuming post treatments. Therefore, heat treatment in vacuum is conducted in an

oxygen-free atmosphere. In addition to the use of high-purity protective gases, vacuum allows the best protection against oxidation.

Due to limited time, here I shall discuss only the hardening and nitriding processes for dies and molds

made out of H-13 steel.

Dies/Molds or other tool steel components are loaded on top of a tray made for this purpose in furnaces

along with a test sample. After closing the door the atmospheric pressure/air in the chamber is removed

automatically by using vacuum pumps.

Figure: 5 HMI System Screens

25

Load Tray (L-885, W-585mm)Test Sample Job Loading Furnace Engineer panel

As the required vacuum level (10-3mbar) is achieved, the selected reciepe/programme is run to meet required hardening process which contains fallowing steps.

During purging segment duly evacuated furnace chamber is backfilled with inert gas to an ambient pressure. This is done to provide better quality of the furnace atmosphere and a higher vacuum level for removing any trace of air or humidity in the furnace chamber.

The temperature of furnace is raised by employing a convection fan to 650°C while keeping the pressure of inert gas at two bars (max).

Under this step the temperature of furnace is further raised to 850°C under vacuum 10-1mbar.

This is the last step of continues heating during which temperature of the furnace is raised to about 10300C under controlled partial pressure of inert gas. Soaking time of 30 minutes for each inch thickness of components is allowed now to bring them in austenitic range (hardening temperature).

This is a quenching process but the quenching media is now nitrogen gas which is sprayed on heated stock at a pressure 5 bars to obtain best martensitic structure.

(a)Nitrogen Purging:

(b) 1st Stage / Gas Heating:

(c)Vacuum Heating:

(d) Partial Pressure Heating:

(e) High Speed Cooling:

Recipe/programme of H-13 Trends of H-13

Tempering Process:The process of tempering is best carried out in these furnaces to:

(1) Remove thermal stresses induced in the stock due to quenching.(2) Convert any retained austenite into fully martensitic structure.

To achieve above results the tempered stock is again heated to about

5700C under an environment of nitrogen. Proper soaking time is

allowed as per thickness of the material and then slow speed cooling

26

27

Nitriding for H-13Hardening with two tempering Nitrided GearsHardening with three tempering

is done with nitrogen at 2 bars. Hardness in the range of 44-48 HRC can be achieved by following reciepe. To get still better structure, 2nd cycle of tempering is also carried out as per figure number 12.

This is a special case hardening process that depends on the absorption of nitrogen into steel components. All sort of

machining, stress relieving, as well as hardening & tempering processes are normally carried out before nitriding.

The parts are heated in a vacuum chamber through which ammonia gas is allowed to pass. The Ammonia is split at

4900C into hydrogen and nitrogen and the atomic nitrogen creates bonds with nitriding forming elements

penetrating the surface to form nitrides.Nitriding steel offers many advantages: a much higher surface hardness is obtainable when compared with case

hardening steels; they are extremely resistant to abrasion and have high fatigue strength.

Vacuum Nitriding process

In nitriding process, same steps are taken till the 1st stage i.e. (gas heating), which were adapted while doing

hardening of components. Later on further processing is carried out as explained now:

Purging with ammonia gas which dissociates at 4900C.

During this segment nitriding procedure is carried out in stages. Stage one is carried out at temperature of about

5100C in which nitrogen is diffused at low rate of diffusion, in order to avoid formation of white layer, which is brittle.

Stage 2 nitriding is carried out for long term diffusion at a temperature higher than stage one as it diffuses more

nitrogen into components. As a result of above treatment, a nitrided layer of 0.1mm to 0.15mm thick is formed with

HRC in the range of about 65-67..

(a)Ammonia Purging:

(b) Stage 1 & Stage 2 Nitriding:

Reciepe/programme Nitriding Trends H-13 Nitriding

(c) Nitrogen Purging:

(d) Blower Cooling:

(e) End of Cycle:

After completing the nitriding process, nitrogen purging is carried out and at the same time temperature is brought down from 5500C to 4500C.

Cooling in nitrogen gas with external gas blower at pressure of 0.05 bars.

End of nitriding cycle and readiness for unloading.

Hardened & Nitrided Jobs:

Nitriding results H-13

59th IFEX 2011 was attended by over 1300 delegates from

India & abroad. International Foundry Exhibition 2011 had

four country pavilions i.e. Italy, Japan, China and Germany

along with 204 companies from India and abroad. The

delegates were from Leading Foundry Units, Pan India,

Leading equipment & material suppliers, Foundry

Consultants etc. Trade delegation from Italian Trade

Commission and VDMA Germany, Pakistan Foundry

Association and China Foundry Association also

participated in both the events.

A Fifteen Member Delegation of Pakistan Foundry

Association has participated in 59th IFEX 2011 on Feb 11 to 13, 2011. The delegation from PFA was very well received

by the organizers and called on at the stage for the WELCOME & Introduction. In the Inaugural Ceremony on 11th Feb

2011, it is worth mentioning that Shri Pawan Kumar

Bensal, honourable Minister for Parliamentary Affairs,

Science and Technology and Earth Sciences, Govt. of India

in his inaugural address welcome and thanked PFA

delegation for their participation. Overall it was a very

successful event from the feed back received. Several

useful businesses enquires generated for supply of cast and machined components, foundry equipments, materials & services which will give fillip to the Indian

foundry industry. Total serious business enquiries were

generated Rs. Four fifty crore (450,0000000/-).

The main highlights were plenary session on “foundry resurgence- India and Energy conservation in foundries, along

with 45 technical papers presented by authors & speakers in 12 technical sessions on Foundry Processes, innovative

technologies, quality improvement, raw materials

scenario, applications of computers in foundry industry, energy economy and pollution control.

PFA is highly obliged and thankful for the favour by Mr. A.K.

Anand – Director, Indian Institute of Foundrymen for his

support in getting visa for our delegate members and Vinay

Kumar Luthra - Gargi, India for his visit to 3rd IFCE 2010 and

invitation and for extending favour for Hotel reservation

etc in 59th IFEX 2011.

59th Indian Foundry Congress (IFC) 2011

59th Indian Foundry Congress & International Foundry ExhibitionFeb. 11th to 13th - 2011 in Chandigarh, India (IFEX 2011)

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